Building component construction

ABSTRACT

A unitary wall or floorlike building component is provided in the form of a main wall element connected to a plurality of parallel stud members by parallel connector portions perpendicular to the wall element and the stud members between which horizontally extending access openings for heating, plumbing or electrical components are provided. The building component can be either of unitary poured construction or can be formed of plural component block units held together by mortar or adhesive with another feature residing in having block units formed of plastic box frames with internal plate bracing fixed on the interior of the box frames for lightness and strength; another aspect of the invention resides in a thin brick plate facade attached to the outer surface of the wall element with the brick plates being embedded in a mortar surface and being of substantially thin construction while having the appearance of full size bricks.

[ 1 June 19, 1973 Unite States Patent n91 Andrews BUILDING COMPONENT CONSTRUCTION Primary ExaminerPrice C. Faw, Jr.

Attorney-Mason, Fenwick & Lawrence [76] Inventor:

ABSTRACT [22] Filed:

A unitary wall or floorlike building component is provided in the form of a main wall element connected to a plurality of parallel stud members by parallel connector portions perpendicular to the wall element and the stud members between which horizontally extending access openings for heating, plumbing or electrical components are provided. The building component can be either of unitary poured construction or can be formed of plural component block units held together by mortar or adhesive with another feature residing in having block units formed of plastic box frames with internal plate bracing fixed on the interior of the box frames for lightness and strength; another aspect of the 4 4 XX 1 u m mm 2 y 2 5m 22 5 1 0 E2 E4 6 m. 2H mm6w S m m5 m2 5 "W6 N m nu E" u 2 m d u 2 m" 0 MM m. l 1 "u n N /O S m m 9 m "M 2 fi A 2m "5 e or u 1 PT re m fi .RSBP u e H u mm D .r. E8 0 4 3% 96 99 SO I m s NH U Un9 d .l. 5 mn 31 U IF 58 v a 74 3 UN H mm D 55 U 2 3 invention resides in a thin brick plate facade attached 52/606 X to the outer surface of the wall element with the brick plates being embedded in a mortar surface and being FOREIGN PATENTS OR APPLICATIONS 3,221,457 12/1965 Vevoda....... 3,391,507 7/1968 Downing...........................

of substantially thin construction while having the ap- 643,152 5/1928 52/439 pearance of full size bricks. 853,432 10/1970 Canada................................. 52/439 7 Claims, 21 Drawing Figures mammm 3.739.541

INVENTOR ZAMomr F. fln/oesws ATTORNEYS amass mvamon ZAMo/vr A Awoesms BY I ime ATTORNEYS PAIENIEB I 9575 BUILDING COMPONENT CONSTRUCTION This invention is in the field of building components and is specifically directed to unitary wall-like or floorlike components which can either be fabricated on the site or fabricated at a central industrial location. The components are either unitarilypoured or can be formed of sub-component block assemblies which are subsequently bonded together with both types of construction being in the form of a main wall element separated from plural parallel stud members by a plurality of connector portions which define access openings through which electrical or plumbing components can be easily positioned during construction of the buildmg.

In conventional construction with timber studs, it is necessary for an electrician or plumber to drill special holes through the wall or floor stud members for enabling insertion of electrical'cable or plumbing piping to extend through the wall or floor. The labor involved in making such openings is considerable and a substantial savings in cost could be achieved if the electrical components and plumbing components could be merely inserted in the wall or floor without the necessity of forming the holes in the studs for receiving same;

it is this desirable result which the instant invention, in one of its aspects, enables.

Another aspect of the invention is derivative from the fact that the concrete construction is of substantial weight and the cost of transporting the pre-assembled building components or of transporting concrete blocks to the site is substantial even for the shortest distances. Therefore, there has remained an unmet need for lightweight building block components, which need, the subject invention answers.

Therefore, it is the primary object of this invention to provide a new and improved building component that is versatile, easy and economical to use.

The manner in which obtainment of the objects of this invention by the preferred embodiments is enabled will be better understood when the following written description is read in conjunction with the drawings in which:

FIG. 1 is an exploded perspective of a first embodiment; FIG. 2 is a front perspective of different subcomponents employed in the embodiment of FIG. 1;

FIG. 3 is an elevational view of the embodiment of FIG. 1 taken from the inside of a building;

FIG. 4 is a sectional view taken along lines 4-4 of FIG. 3;

FIG. 5 is an inside perspective view illustrating the manner of attachment of a roof plate to the embodiment of FIG. 1;

FIG. 6 is a sectional view taken along lines 66 of FIG. 3;

FIG. 7 is a perspective view of an adapter member usable with the embodiment of FIG. 1 for attaching electrical or structural accouterments;

FIG. 8 is a sectional view taken along lines 8-8 of FIG. 3;

FIG. 9 is a perspective view of a second attachment used for attaching cabinets or the like to the wall construction;

FIG. 10 is a perspective view of a sub-component unit block member;

FIG. 11 is a perspective view of a half unit block subcomponent block member;

FIG. 12 is a perspective view of sub-component spacer block members;

FIG. 13 is a perspective view of a second embodiment of the invention;

FIG. 14 is a horizontal sectional. view of a corner construction of theembodiment of FIG. 13;

FIG. 15A is a perspective view illustrating the initial step in the formation of a particular type building com- Attention is initially invited to FIG. 1 of the drawings 7 which illustrates a preferred embodiment of the invention in the form of three perpendicular building wall components each respectively supported on linear foundation members 10,11 and 12 and constructed of a plurality of sub-component block members bonded together to form a unitary construction.

Each building wall component includes a main external wall element 20 having an outer surface 22 and an inner surface 24 with the main wall elements 20 being formed, for the most part, of a plurality of main wall sub-component members 30 of individual unit block sub-components 28 (FIG.2).

Additionally, each wall component includes a plurality of vertically extending stud members 26 which are arranged in parallel relationship to each other and to the main wall element 20. Each of the stud members 26 is formed of a plurality of stacked vertically aligned stud sub-components with each stud sub-component being apart of a sub-component block.

Specifically, the unit block sub-component members 28 each have a main wall component 30 and first and second end connector block means 32 extend perpendicularly from the inner surface 24 of the wall component 30 and half-stud width stud components 34 extend unitarily from the end connector blocks 32 in parallel relationship with respect to each other as best shown in FIG. 10. The end connector block members 32 and members 26 are of a width equal to one-half the full width of the component stud members 26.

Additionally, the unit block members 28 are provided with an intermediate connector block 36 of a full stud width and from which a full stud width stud component 38 (FIGJ) unitarily extends in parallel relationship to the half stud width stud components 34.

FIG. 5 illustrates the manner in which the subcomponent block members are arranged in parallel horizontal courses A, B and C with the blocks in course A being staggered with respect to the blocks in course B and the blocks in course C being positioned in alignment with those of course A. Specifically, it should be noted that the full width stud components 38 of course A overlie two abutting adjacent half-stud width components 34 in course B. Similarly, the full width stud components 38 of course B cooperate with the half stud width components 36 of course A and C to provide a resultant vertical stud 26 to which an interior wall board 39 can be attached. Obviously, the overlapping relationship of the unit block members 28 cannot, in and of themselves, result in a smooth end or corner construction and it is necessary to provide spacer and sub-unit blocks of the type shown in FIGS. 10, 11 and 12 for filling in the less than unit block length spaces in elements being formed of the components. Such spacer block components comprise one-half stud width spacer blocks 40 (FIG.12) each having a'main wall component 30, a connector component 32' and a half stud width component 36 all of which are equal to one half the stud width. The use of such a one-half stud width block 40 is shown in FIG. 3.

Additionally, full stud width spacer blocks 42 (FIG.12) have a main wall component 30" and connector blocks 32" unitarily formed with full stud width components 38". It should be noted that all of the components of block 42 are of a width equal to the full stud width.

Similarly, spacer blocks 44 (FIG.12) having a width equal to the spacing between adjacent studs 26 are also provided with each spacer block 44 including a main wall component 30", a connector block component 32" and a corner post component 46 all of which are of width equal to the spacing between adjacent parallel stud members 26.

In like manner, one-half unit block members 48 illustrated in FIGS. 11 and 3 are also provided for use in the component wall structure. The half unit block members 48 are provided with main wall components 30A and with first and second end connector blocks 32A extending unitarily outwardly therefrom and one-half stud width stud components 34A formed unitarily on the ends of connector blocks 32A.

Additionally, right hand external corner blocks 50 (FIGJ) are provided for use in corner construction and left hand external corner blocks 52 are similarly provided for use in the manner shown in FIG. 1. The right hand external corner blocks 50 are identical to the unit blocks 28 with the exception that the right end of the blocks 50, as viewed from the interior, is provided with a main wall corner component 30B in place of the connector block and end stud components of the unit blocks 28. Similarly, the left hand external corner blocks 52 are identical to the right hand external corner block 50 with the exception that a main wall corner component 30C is provided on the left end of the block rather than the right end as is the case with component 30B of block 50.

Additionally, right and left hand internal corner blocks 54 are provided for the internal comers as shown in FIG. 1. The right and left hand internal corner blocks each include a shortened main wall component 30D and an internal comer post plate 56. The internal corner post plate 56 is separated from the main wall component 308 by a space 58 and it is to be noted that the internal corner blocks 54 are provided with right and left hand orientations with respect to the position of the internal corner post plate 56 with the blocks employed in adjacent corners being of different orientations as shown in FIG. 1. Also, each of the internal corner blocks 54 is provided with a full stud width component 38 and an end stud component 34 of A stud width.

FIG. 2 illustrates two unit block members in which a decorative facade F has been applied to the main wall components 30. The employment of such a facade provides a continuous smooth decoration on the external portion of the wall which appears to be completely continuous notwithstanding the fact that it is formed of the plural sub-components. This appearance is enabled by virtue of the fact that the blocks are prefereably connected together by adhesive such as epoxy or the like along exactly smooth facing surfaces.

It should be noted that the open space between the stud components of each block and the main wall components provides a horizontalpassageway along each course of blocks through which plumbing and electrical components can be inserted. For example, FIG. 3 of the drawings illustrates a conduit 60 extending along the second course above the foundation 62.

FIG. 3 also illustrates the manner in which a window frame 62 can be mounted in a wall formed of the component blocks. Specifically, a retainer plate 64 having dimensions larger than the horizontally extending access openings is provided for engagement with the block members with a threaded screw 66 extending through an opening in the plate 64 into the window frame 62. A door frame could be mounted in essentially the same manner.

FIG. 3 also illustrates the use of a V2 stud width spacer block 40, a stud spacer block 44 and a A unit block member 48 in conjunction with a left hand external corner block 52 to provide the proper spacing of the window frame from the left edge of the wall.

FIG. 5 illustrates the manner in which a roof plate 150 is attached to the top of a wall by means of a J- shaped rod 152 extending upwardly through the plate 150 and held in position by a nut 154 on its upper end with the lower end being provided with a hook insertable through an access opening for engagement with the connector block components of the wall member.

Additionally, the open access opening provided in each block between the main wall components and the stud components also enables the mounting of various other building components in a remarkably convenient manner. For example, a switch fixture support connector bracket 66 illustrated in FIG. 7 can be easily inserted in the access opening by means of a U-shaped male box frame portion 68 which has an outside dimension snugly receivable within the confines of any of the access openings. The male portion 68 is connected to a support plate 70 to which an electrical circuit switch box 72 or the like can be attached in the manner shown in FIG. 3. Utility line components such as electrical cable 74 from the switch can easily be passed through the access openings in the course of blocks above the switch box as shown.

For supporting larger items such as cabinets or the like, a larger support plate 76 can be provided between two male portion components 78 which are insertable in the access openings in the block members. The plate 76 is connected to the male portion 78 by means of extension legs 80. FIGS. 6 and 8 respectively show the mounting of the previously discussed accessory components as viewed from above.

While the preceding discussion has been directed to solid sub-component block members, FIGS. 17-19 illustrate a modified version of the block subcomponents in which the blocks are of lightweight plastic. The specific construction comprises a wall component 80 formed of a closed plastic box shell frame 82 of rectangular configuration having a top and bottom and end portions interconnected as shown in FIG. 17

and a thin wall plate 84 having a decorative facade plate 86 attached externally thereof. The wall portion 80 also includes first and second internal diagonal brace plates 88 and a bisecting brace plate 90. The connector components of the plastic block construction illustrated in FIGS. 17-19 comprise upper and lower plastic channel members 100 extending from the wall portion 80 and having plastic stud components 102 along their rearward termination. The members '100 and 102 are all formed of plastic box frames comprising horizontal outer frame plates 104, horizontal inner frame plates 106, corner connecting diagonal frame plates 108, external vertical plates 110, internal vertical plates 114 and a horizontal internal plate 116. The width of the component 104 etc. is equal to one-half the width of a stud and two of the connector portions and sub-component portions are provided in facing relationship medially of the wall portion 80 to provide a resultant full width stud as shown in FIGS. 17-19. A U- shaped closure plate 117 is on opposite sides of the two intermediate members so that the resultant stud is formed of a series of hollow portions. This plastic construction is of great strength and rigidity per unit weight and can be assembled to provide a remarkably attractive wall section in a quick and easy manner. Normally, the plastic components would be secured together by adhesive such as epoxy or the like. Alternately, they could be bolted through holes provided therein.

FIG. 13 illustrates an alternative form of wall component construction in which the wall is formed of a solid poured member as opposed to the previously discussed component formed of the sub-component block members.

The wall member of FIG. 13 includes a mainwall element 120 having an outer surface 122 and inwardly facing surface 124 with these two surfaces being analagous to the surfaces 22 and 24 of the sub-component block construction previously discussed. Vertical stud members 126 are provided to extend parallel to each other spaced from the inner surface 124 with a plurality of access apertures or openings 128 being formed between the stud members 126 and the mainwall component 120. Adjacent wall sections can be connected together as shown at line 130 by means of threaded rods extending through the adjacent access openings and maintained in position by retainer plates 132 and nuts 134 on the ends of the rods 136 in an obvious manner.

A corner construction of the poured slab embodiment is illustrated in FIG. 14 with threaded lug rods 137 being embedded in the main wall component 120 to be held in position by retainer plates 132 and nuts 134 in an obvious manner. The complete poured construction is susceptible to various modifications and use with accessories employed with the sub-component constructions as discussed previously.

Additionally, the prepoured construction is more easily provided with a decorative facade on its external wall surface 124 than is the sub-component system. FIGS. A',15B, 15C and 16 illustrate the manner in which such a decorative facade can be provided.

FIG. 15A illustrates the initial step by which a layer of mortar 140 is applied to the outer surface 122. A template lattice member 142 formed of metal rods is then positioned over the mortar layer 140 and a plurality of brick plates 144 are then positioned in openings in the lattice to be immersed in the mortar 140. The brick plates 144 each have end edges 146 in which a groove 148 is provided. Grooves 148 serve to receive the mortar 140 which, upon hardening, serves to retain the brick plates 144 in position in an obvious manner.

The distance between the externalface 150and inter- It should be understood that thesubject invention is susceptible to various modifications as will be obvious to those skilled in the art and the spirit and scope of the invention is to be determined solely by the appended claims.

I claim:

1. A generally planar building component comprising a main wall element having an outer surface and an inner surface and a plurality of parallel stud members connected to said inner surface by a plurality of connector portions extending inwardly perpendicularly from said inner surface with each stud member having an inwardly facing surface and an exterior surface, said connector portions being placed from each other and in aligned relationship to define in conjunction with said stud members and said inner surface of said main wall a plurality of access apertures arranged in parallel spaced lines of' alignment extending in a first direction parallel to said inner surface and perpendicular to said main wall component which cooperates with other main wall components of other unit block members to form said main wall of said building component, first and second end connector block means extending inwardly perpendicularly from said main wall component adjacent each end of said main wall component and an intermediate connector block means extending inwardly from said main wall component intermediate said first and second end connector blocks, said first and second end connector blocks being of A stud width and having a half-stud width stud component extending unitarily from their innermost ends and said intermediate connector block having a full width stud compo nent extending unitarily from its end opposite its connection to said main wall component whereby adjacent courses of said sub-component block members are in overlapped array and adjacent block membersof each course have adjacent A stud width blockcomponents in engagement to define a full width stud portion.

2. The invention of claim 1 wherein said subcomponent block members additionally include half unit width block members each having first and second end connector blocks extending. perpendicularly from the inner surface of said main wall component and Va stud width stud block components unitarily extending along the end of said first and second connector blocks of said half unit block members.

3. The invention of claim 2 wherein said subcomponent block members additionally include stud width spacer block membersof uniform width throughout each comprising a main wall component, a connector component and a stud component.

lar to said first building component, said corner block sub-component block members each comprising a major main wall component, a minor main wall component extending normal from said major main wall component perpendicular thereto from one end of said major wall component, an end connector block extending inwardly perpendicularly from said major main wall component adjacent the opposite end of said major wall component, an intermediate connector block extending inwardly from said major wall component interrnediate the end connector block and said minor wall component, said end connector block being of one-half stud width and said intermediate connector block being of full stud width and a full stud width component extending unitarily from said intermediate connector block ;a half stud width component extending unitarily from said end connector block.

6. The invention of claim 5 wherein said subcomponent block members include one-half stud width spacer blocks of thickness equal to 0nehalf the stud width throughout, each h stud width spacer block including a main wall component, a connector block and a stud component.

7. The invention of claim 1 wherein said first and second end connector block means and said stud portions are connected together to form a unitary U-shaped construction extending from said main wall component. 

1. A generally planar building component comprising a main wall element having an outer surface and an inner surface and a plurality of parallel stud members connected to said inner surface by a plurality of connector portions extending inwardly perpendicularly from said inner surface with each stud member having an inwardly facing surface and an exterior surface, said connector portions being placed from each other and in aligned relationship to define in conjunction with said stud members and said inner surface of said main wall a plurality of access apertures arranged in parallel spaced lines of alignment extending in a first direction parallel to said inner surface and perpendicular to said stud members for enabling an easy insertion of utility line components through said access openings, said building component being formed of a plurality of sub-component block Members bonded together to form a unitary construction, and said sub-component block members include unit block members each having a main wall component which cooperates with other main wall components of other unit block members to form said main wall of said building component, first and second end connector block means extending inwardly perpendicularly from said main wall component adjacent each end of said main wall component and an intermediate connector block means extending inwardly from said main wall component intermediate said first and second end connector blocks, said first and second end connector blocks being of 1/2 stud width and having a half-stud width stud component extending unitarily from their innermost ends and said intermediate connector block having a full width stud component extending unitarily from its end opposite its connection to said main wall component whereby adjacent courses of said subcomponent block members are in overlapped array and adjacent block members of each course have adjacent stud width block components in engagement to define a full width stud portion.
 2. The invention of claim 1 wherein said sub-component block members additionally include half unit width block members each having first and second end connector blocks extending perpendicularly from the inner surface of said main wall component and 1/2 stud width stud block components unitarily extending along the end of said first and second connector blocks of said half unit block members.
 3. The invention of claim 2 wherein said sub-component block members additionally include stud width spacer block members of uniform width throughout each comprising a main wall component, a connector component and a stud component.
 4. The invention of claim 3 wherein said sub-component block members include one-half stud width spacer blocks of thickness equal to one-half the stud width throughout, each 1/2 stud width spacer block including a main wall component, a connector block and a stud component.
 5. The invention of claim 2 additionally including corner block sub-component block members for connecting one edge of said building component to an edge of a second building component oriented perpendicular to said first building component, said corner block sub-component block members each comprising a major main wall component, a minor main wall component extending normal from said major main wall component perpendicular thereto from one end of said major wall component, an end connector block extending inwardly perpendicularly from said major main wall component adjacent the opposite end of said major wall component, an intermediate connector block extending inwardly from said major wall component intermediate the end connector block and said minor wall component, said end connector block being of one-half stud width and said intermediate connector block being of full stud width and a full stud width component extending unitarily from said intermediate connector block ;a half stud width component extending unitarily from said end connector block.
 6. The invention of claim 5 wherein said sub-component block members include one-half stud width spacer blocks of thickness equal to one-half the stud width throughout, each 1/2 stud width spacer block including a main wall component, a connector block and a stud component.
 7. The invention of claim 1 wherein said first and second end connector block means and said stud portions are connected together to form a unitary U-shaped construction extending from said main wall component. 